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Engine Assembly: Removal

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE 
  2. REMOVE BATTERY 
    1. Disconnect the cable from the battery terminal.
    2. Loosen the nut and remove the battery clamp.
    3. Remove the battery.
  3. REMOVE BATTERY TRAY 
  4. REMOVE FRONT WHEELS 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE ENGINE UNDER COVER RH 
  7. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  8. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)  (See REMOVAL )
  9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)  (See REMOVAL )
  10. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  11. REMOVE FRONT WIPER ARM LH  (See REMOVAL )
  12. REMOVE FRONT WIPER ARM RH  (See REMOVAL )
  13. REMOVE HOOD TO COWL TOP SEAL (for Hatchback)  (See REMOVAL )
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback)  (See REMOVAL )
  15. REMOVE COWL TOP VENTILATOR LOUVER LH (for Hatchback)  (See REMOVAL )
  16. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan)  (See REMOVAL )
  17. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan)  (See REMOVAL )
  18. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan)  (See REMOVAL )
  19. REMOVE FRONT WIPER MOTOR AND LINK  (See REMOVAL )
  20. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO. 2 (for Hatchback) 
    1. Disengage the claw and remove cowl to register duct sub-assembly No. 2.
      Fig 1: Identifying Cowl To Register Duct Sub-Assembly
      G04828727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT AIR SHUTTER SEAL RH (for Sedan) 
    1. Disengage the 3 claws and remove the front air shutter seal RH.
      Fig 2: Identifying Front Air Shutter Seal Claws
      G04828449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE COWL TOP PANEL OUTER (for Hatchback) 
    1. Disengage the wire harness clamp.
      Fig 3: Identifying Wire Harness Clamp
      G04828729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9 bolts and remove the cowl top panel outer.
      Fig 4: Locating Cowl Top Panel Outer
      G04828730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE COWL TOP PANEL OUTER (for Sedan) 
    1. Disengage the wire harness clamp.
      Fig 5: Identifying Wire Harness Clamp
      G04828731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and remove the cowl top to cowl inner brace.
      Fig 6: Locating Cowl Top To Cowl Inner Brace
      G04828732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 8 bolts and remove the cowl top panel outer.
      Fig 7: Locating Cowl Top Panel Outer
      G04828733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE AIR CLEANER ASSEMBLY 
    1. Separate the intake air flow meter connector and the wire harness clamp.
    2. Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly.
    3. Separate the vacuum switching valve connector and the wire harness clamp.
    4. Separate the ventilation hose from the air cleaner hose.
    5. Release the air cleaner cap sub-assembly with air cleaner hose No. 1.
    6. Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and the air cleaner hose.
    7. Remove the air cleaner element.
    8. Separate the wire harness clamp from the air cleaner case.
    9. Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1.
      Fig 8: Locating Intake Air Flow Meter Connector And Wire Harness Clamp
      G04828734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 9: Locating Air Cleaner Hose Clamp
      G04828735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE AIR CLEANER BRACKET 
    1. Separate the wire harness clamp from the air cleaner bracket.
    2. Remove the 2 bolts and remove the air cleaner bracket.
      Fig 10: Locating Air Cleaner Bracket
      G04828736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BATTERY CARRIER 
    1. Separate the wire harness clamp from the battery carrier.
    2. Remove the 5 bolts and remove the battery carrier.
      Fig 11: Locating Battery Carrier
      G04828737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT RADIATOR HOSE NO. 3 
    1. Disconnect radiator hose No. 3 from the water filler.
      Fig 12: Locating Radiator Hose From Water Filler
      G04828738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT RADIATOR RESERVOIR TANK HOSE 
    1. Disconnect the radiator reservoir tank hose from the water filler.
      Fig 13: Locating Radiator Reservoir Tank Hose From Water Filler
      G04828739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT RADIATOR HOSE NO. 2 
    1. Disconnect radiator hose No. 2 from the water inlet.
      Fig 14: Locating Radiator Hose From Water Inlet
      G04828740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle) 
    1. Loosen the clip and disconnect the oil cooler outlet hose.
      Fig 15: Locating Oil Cooler Outlet Hose
      G04828741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle) 
    1. Loosen the clip and disconnect the oil cooler inlet hose.
      Fig 16: Locating Oil Cooler Inlet Hose
      G04828742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CYLINDER HEAD COVER NO. 2  REMOVAL 
  33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  35. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the union to check valve hose from the booster vacuum tube.
  36. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Disconnect heater water outlet hose A from the heater unit.
      Fig 17: Locating Heater Water Outlet Hose From Heater Unit
      G04828743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect heater water inlet hose A from the heater unit.
      Fig 18: Locating Heater Water Inlet Hose From Heater Unit
      G04828744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove fuel pipe clamp No. 1.
      Fig 19: Identifying Fuel Pipe Clamp
      G04828745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
      NOTE:
      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull to release them.
        Fig 20: Pulling Fuel Tube Connector Out Of Pipe
        G04828746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FAN AND GENERATOR V BELT (See REMOVAL  )
  40. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System) 
    1. Disconnect the connector.
    2. Remove the 4 bolts and separate the with pulley compressor assembly.

      HINT:

      Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope.

  41. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  42. DISCONNECT ENGINE WIRE 
    1. Pull up the lever and disconnect the connector of the engine control computer.
      Fig 21: Disconnecting Connector Of Engine Control Computer
      G04828747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 connectors and the clamp from the engine room junction block and disconnect the wire harness.
      Fig 22: Identifying Connectors And Clamp From Engine Room Junction Block
      G04828748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and separate the earth wire of the engine room wire harness.
    4. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.
      Fig 23: Locating Engine Room Wire Harness Bolt
      G04828749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  44. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY  (See REMOVAL )
  45. REMOVE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1  (See REMOVAL )
  46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) 
  47. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  48. REMOVE CONSOLE BOX REAR COVER (for Hatchback)  (See REMOVAL )
  49. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan)  (See REMOVAL )
  50. REMOVE INSTRUMENT PANEL FINISH PANEL END LH (for Sedan)  (See REMOVAL )
  51. REMOVE INSTRUMENT PAD LOWER LH (for Sedan)  (See REMOVAL )
  52. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan)  (See REMOVAL )
  53. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan)  (See REMOVAL )
  54. REMOVE CONSOLE BOX CARPET (for Sedan)  (See REMOVAL )
  55. REMOVE REAR CONSOLE BOX ASSEMBLY  REMOVAL 
  56. REMOVE HEATED OXYGEN SENSOR  (See REMOVAL )
  57. REMOVE EXHAUST PIPE ASSEMBLY FRONT  (See REMOVAL )
  58. REMOVE FRONT AXLE HUB LH NUT  (See REMOVAL )
  59. REMOVE FRONT AXLE HUB RH NUT  (See REMOVAL )
  60. SEPARATE SPEED SENSOR FRONT LH (w/ ABS)  (See REMOVAL )
  61. SEPARATE SPEED SENSOR FRONT RH (w/ ABS)  (See REMOVAL )
  62. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See REMOVAL )
  63. SEPARATE TIE ROD END SUB-ASSEMBLY RH  (See REMOVAL )
  64. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  65. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH  (See REMOVAL )
  66. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH  (See REMOVAL )
  67. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH  (See REMOVAL )
  68. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  69. SEPARATE FRONT AXLE ASSEMBLY RH  (See REMOVAL )
  70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  71. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  72. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle) 
  73. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) 
    1. Remove the 6 torque converter set bolts.
      Fig 24: Locating Torque Converter Set Bolts
      G04828750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      Fig 25: Identifying Engine Lifter
      G04828751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and the nut and remove the engine mounting insulator RH.
      Fig 26: Locating Engine Mounting Insulator RH
      G04828752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and the nut and separate the engine mounting insulator LH.
      Fig 27: Locating Engine Mounting Insulator LH
      G04828753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts, and remove the engine assembly with transaxle and the front suspension crossmember from the vehicle.
  75. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the bolt and remove the radio setting condenser.
    2. Remove the bolt and remove the oxygen sensor wiring bracket.
      Fig 28: Locating Oxygen Sensor Wiring Bracket And Bolt
      G04828754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine hangers with the bolts, as shown in the illustration.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      Part No.: 12281-21010 for engine hanger 91642-81025 for bolt

    4. Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.
    5. Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.
      Fig 29: Identifying Engine Hangers With Bolts
      G04828755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE VENTILATION HOSE 
    1. Loosen the 2 clips and remove the ventilation hose.
  77. REMOVE VENTILATION HOSE NO. 2 
    1. Loosen the clips and remove ventilation hose No. 2.
  78. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Disengage the claw and remove fuel pipe clamp No. 2.
      Fig 30: Identifying Fuel Pipe Clamp
      G04828756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the fuel tube connector retainer from both sides, disconnect the fuel tube connector and separate the fuel tube from the pipe.
      NOTE:
      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull to release them.
        Fig 31: Locating Fuel Tube Connector Retainer
        G04828757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE WATER FILLER SUB-ASSEMBLY 
    1. Disconnect radiator hose No. 1 from the cylinder head.
    2. Remove the 2 nuts and remove the water filler sub-assembly.
  80. REMOVE HEATER WATER INLET HOSE A 
    1. Disconnect heater water inlet hose A from the cylinder head.
  81. REMOVE FLYWHEEL HOUSING SIDE COVER  (See REMOVAL )
  82. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 
    1. Remove the 7 bolts and remove the automatic transaxle with torque converter.
      Fig 32: Locating Automatic Transaxle With Torque Converter
      G04828758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Hold the crankshaft with SST.

      SST 09960-10010 (09962-01000, 09963-01000) 

    2. Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR.
      Fig 33: Holding Crankshaft With SST
      G04828759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE CONTROL CABLE BRACKET (for Manual Transaxle)  (See REMOVAL )
  86. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  87. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  88. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
  89. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Hold the crankshaft with SST.

      SST 09960-10010 (09962-01000, 09963-01000) 

    2. Remove the 6 bolts and flywheel.
  90. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
  91. REMOVE IGNITION COIL NO. 1 
    1. Disconnect the connectors of the ignition coils.
    2. Remove the bolt and remove all the ignition coils.
  92. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
    Fig 34: Holding Crankshaft With SST
    G04828759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. REMOVE INTAKE MANIFOLD 
    1. Disconnect the union to connector tube hose from the booster vacuum tube.
    2. Disconnect the engine wire from the intake manifold.
      Fig 35: Locating Engine Wire From Intake Manifold
      G04828761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the water bypass hose from the cylinder head.
      Fig 36: Locating Water Bypass Hose From Cylinder Head
      G04828762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the water bypass hose from water bypass pipe No. 1.
    5. Disconnect the throttle with motor body assembly connector.
      Fig 37: Locating Motor Body Assembly Connector
      G04828763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 bolts and 2 nuts in the order shown in the illustration and remove the intake manifold.
    7. Remove the gasket from the intake manifold.
      Fig 38: Identifying Intake Manifold
      G04828764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. REMOVE WATER BYPASS PIPE NO. 1 
    1. Remove the 2 bolts and 2 nuts and remove water bypass pipe No. 1.
      Fig 39: Locating Water Bypass Pipe
      G04828765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE BOOSTER VACUUM TUBE 
    1. Remove the 2 bolts and remove the booster vacuum tube.
  96. REMOVE ENGINE WIRE 
    1. Disconnect all the sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness.
      Fig 40: Locating Booster Vacuum Tube
      G04828766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 2 bolts and remove the 2 wire harness clamp brackets.
  98. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Remove the 4 bolts and remove the exhaust manifold heat insulator.
  99. REMOVE MANIFOLD SUPPORT BRACKET 
    1. Remove the 3 bolts and remove the manifold support bracket.
  100. REMOVE EXHAUST MANIFOLD 
    1. Remove the 3 bolts and 2 nuts and remove the exhaust manifold.
      Fig 41: Locating Exhaust Manifold Heat Insulator
      G04828767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY 
    1. Remove the bolt and nut and remove the drive shaft heat insulator.
      Fig 42: Locating Drive Shaft Heat Insulator
      G04828768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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